1999 LAND ROVER DEFENDER belt

PANEL REPAIRS
3
PROCEDURES
4.Cut away the bulk of the panel as necessary
using an air saw.
NOTE: On certain panel joints MIG welds
and braze should be removed using a
sander where possible, before cutting out
the panel bulk.
5.Separate spot welded joints and remove panel
remnants using hammer, bolster chisel and
pincers.Prepare Old Surfaces
6.Clean all panel joint edges to a bright smooth
finish, using a belt-type sander.
NOTE: Prior to sanding, remove remaining
sealant using a hot air gun to minimise the
risk of toxic fumes caused by generated
heat.
WARNING: Care must be taken to avoid
excessive heat build up which may be
caused by this equipment.
7.Straighten existing joint edges using shaping
block and hammer.
CAUTION: Where significant straightening
is required, heat must be applied to the
area to avoid stretching the Aluminium.
CAUTION: All tools used for working with
Aluminium must be kept separate from
those used on steel.
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77PANEL REPAIRS
4
PROCEDURES Prepare New Surfaces
8.Prepare new panel joint edges for welding by
sanding to a bright finish. This must include inner
as well as outer faces.
9.Drill holes in new panel, in the equivalant spot
weld positions.
10.Apply adhesive sealant to panel joint surfaces.
11.All mating faces that have sealant applied to
them must be cleaned using a suitable solvent.
The majority of Aluminium sealants have a
primer/pre-treatment included with them.
CAUTION: Do not use Petroleum Spirit,
Alcohol or Paint Thinners to clean mating
faces.Offer Up and Align
Offer up new panel and align with associated panels.
Clamp into position using welding clamps or Mole
grips. Where a joggle or brace joint is being adopted,
make a set in the original panel joint edge or insert a
brace behind the joint.
NOTE: In cases where access for welding
clamps is difficult, it may be necessary to
use tack welds.
12.Dress MIG tack welds using a sander with 36 grit
disc, or a belt-type sander where access is
limited.
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PANEL REPAIRS
5
PROCEDURES Welding
13.When plug welding, begin weld approximately 15
mm (0.6’) from hole. This will allow the weld
area to be preheated which will enhance weld
penetration. It also allows the operator to see
more easily where penetration takes place. Fill
hole with weld by moving in a circular direction
around the hole.
14.When MIG seam welding do not carry out
lengthy operations. Divide the welds into short
operations, this will reduce the chances of
overheating the workpiece which inturn will avoid
distortion and strain.
15.Dress all welds using a sander with 36 grit disc,
or a belt-type sander and/or wire brush.
CAUTION: Only use a Stainless Steel wire
brush for Aluminium.
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PANEL REPAIRS
5
REPAIR SILL - FRONT
Remove
NOTE: The procedure to replace the rear
sill section is the same as the front.
1.Remove bolts securing sill to body, discard seal.
Refit
NOTE: Front sill
NOTE: Rear sill
2.Prepare and clean panel joint faces. Refit new
seal.
3.Reverse removal procedure.’B/C’&’D’POST
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove rear door and striker.
3.Remove front seat belt reel.See CHASSIS
AND BODY, Repair.
4.Remove front and rear carpets.
5.Remove front seat.
6.Remove rear seat.
7.Remove front, centre and rear sections of
headlining.
NOTE: Assembly is held on with bolts.
Refit
8.Prepare and clean panel joint faces.
9.Reverse removal procedure.
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AIR CONDITIONING
1
REPAIR COMPRESSOR
Service repair no - 82.10.20
Remove
1.Remove engine acoustic cover.See ENGINE ,
Repair.
2.Depressurise A/C system.See Adjustment.
3.Remove auxiliary drive belt.See
ELECTRICAL, Repair.
4.Drain cooling system.See COOLING
SYSTEM, Adjustment.
5.Disconnect multiplug from compressor.
6.Remove 2 bolts securing air conditioning pipes
to compressor and discard’O’rings.
CAUTION: Immediately cap all air
conditioning pipes to prevent ingress of
dirt and moisture into the system.
7.Release clips and disconnect top hose from
coolant elbow and heater pipe.
8.Remove 4 bolts securing compressor to
mounting bracket.
9.Remove compressor.Refit
10.Position compressor to mounting bracket and
tighten bolts to25 Nm (18 lbf.ft).
11.Remove caps from compressor and pipe
connections.
12.Clean compressor and pipe connections.
13.Lubricate new’O’rings with refrigerant oil and fit
to compressor.
14.Position A/C pipes to compressor and tighten
bolts to9 Nm (7 lbf.ft).
15.Connect multiplug to compressor.
16.Position top hose and secure with clips.
17.Refill cooling system.See COOLING SYSTEM,
Adjustment.
18.Fit auxiliary drive belt.See ELECTRICAL,
Repair.
19.Recharge A/C system.See Adjustment.
20.Fit engine acoustic cover.See ENGINE ,
Repair.
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86 - ELECTRICAL
CONTENTS
Page
DESCRIPTION AND OPERATION
SECURITY AND CENTRAL DOOR LOCKING 1....................................................
SECURITY AND CENTRAL DOOR LOCKING 2....................................................
ANTI-THEFT ALARM - FROM 02MY 3...................................................................
IMMOBILISATION SYSTEM - FROM 02MY 12......................................................
CENTRAL DOOR LOCKING (CDL) - FROM 02MY 15...........................................
ANTI-THEFT ALARM SYSTEM SELF TEST 17.....................................................
FASCIA CONSOLE 18............................................................................................
HEATED FRONT SCREEN - FROM 02MY 20.......................................................
HEATED FRONT SEATS - FROM 02MY 22..........................................................
ELECTRIC FRONT WINDOWS - FROM 02MY 24.................................................
PASSENGER COMPARTMENT FUSE BOX 26.....................................................
UNDER SEAT FUSE BOX 27.................................................................................
ADJUSTMENT
HEADLAMPS - ALIGN BEAM 1..............................................................................
SOLENOID/MOTOR - FRONT DOOR - ADJUST 1................................................
REPAIR
BELT - AUXILLARY DRIVE 1.................................................................................
HARNESS - INJECTORS 1....................................................................................
STARTER MOTOR 2..............................................................................................
CENTRE HIGH MOUNTED STOP LIGHT (CHMSL) - UP TO 02MY 2...................
ALTERNATOR 3.....................................................................................................
HORN - LH 4...........................................................................................................
HEADLAMP 5.........................................................................................................
LAMP - TAIL 6.........................................................................................................
RADIO6 ..................................................................................................................
SPEAKER - FRONT 7.............................................................................................
SWITCH - TRANSMISSION BRAKE 7...................................................................
LAMP - FRONT FLASHER 8..................................................................................
BATTERY - DISCONNECT - FROM 02MY 8..........................................................
MOTOR & REGULATOR - FRONT DOOR - FROM 02MY 9..................................
SWITCH - FASCIA - FROM 02MY 10.....................................................................
HARNESS - FRONT DOOR - FROM 02MY 10.......................................................
SOLENOID/MOTOR - TAIL DOOR - FROM 02MY 11............................................
SOLENOID/MOTOR - FRONT DOOR - FROM 02MY 12.......................................
SOLENOID/MOTOR - REAR DOOR - FROM 02MY 13.........................................
HARNESS - REAR DOOR - FROM 02MY 14.........................................................
REVERSE AND FOG GUARD LAMP - BULB 15....................................................
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ELECTRICAL
1
REPAIR BELT - AUXILLARY DRIVE
Service repair no - 86.10.03
Remove
1.Remove cooling fan.See COOLING SYSTEM,
Repair.
2.Release drive belt tensioner using a 15 mm ring
spanner and release belt from pulleys.
Refit
3.Clean drive belt pulley grooves and ensure
grooves are not damaged.
4.Fit new drive belt around pulleys, ensure belt is
correctly aligned in pulley grooves.
5.With assistance, hold tensioner fully clockwise
and fit drive belt around remaining pulley.
6.Fit cooling fan.See COOLING SYSTEM,
Repair.HARNESS - INJECTORS
Service repair no - 86.70.22
Remove
1.Remove camshaft cover gasket.See ENGINE ,
Repair.2.Disconnect engine harness from injector
harness.
3.Disconnect multiplugs from injectors.
4.Release injector harness from camshaft carrier
and remove harness.
Refit
5.Fit new’O’rings to injector harness connector.
6.Position harness and locate connector to
camshaft carrier.
7.Connect injector and engine harness multiplugs.
8.Fit camshaft cover gasket.See ENGINE ,
Repair.
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ELECTRICAL
3
REPAIR ALTERNATOR
Service repair no - 86.10.02
Remove
1.Remove auxilliary drive belt.See this Section.
2.Release cover and remove nut securing lead to
alternator.
3.Disconnect alternator multiplug.
4.Remove bolt (LH thread) and remove auxiliary
drive belt tensioner.
5.Remove bolt securing support stay to alternator.
6.Release clip securing lubrication drain hose to
vacuum pump.
7.Loosen vacuum pump lubrication pipe from
cylinder head and discard’O’ring.
8.Remove bolt securing alternator and release
from mounting bracket.
9.Disconnect hose from vacuum pump.
10.Remove alternator taking care not to damage
radiator cooling fins.
11.Remove 4 bolts, and remove vacuum pump from
alternator.
CAUTION: Plug the connections.
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